EP3242762A1 - Dispositif et procédé génératif de construction par couches permettant de produire un objet tridimensionnel au moyen d'une pluralité de rayons - Google Patents

Dispositif et procédé génératif de construction par couches permettant de produire un objet tridimensionnel au moyen d'une pluralité de rayons

Info

Publication number
EP3242762A1
EP3242762A1 EP15819842.4A EP15819842A EP3242762A1 EP 3242762 A1 EP3242762 A1 EP 3242762A1 EP 15819842 A EP15819842 A EP 15819842A EP 3242762 A1 EP3242762 A1 EP 3242762A1
Authority
EP
European Patent Office
Prior art keywords
beams
overlap
subregions
area
areas
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP15819842.4A
Other languages
German (de)
English (en)
Inventor
Gerd Cantzler
Albert Fruth
Bernd LABRENTZ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EOS GmbH
Original Assignee
EOS GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EOS GmbH filed Critical EOS GmbH
Publication of EP3242762A1 publication Critical patent/EP3242762A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/083—Devices involving movement of the workpiece in at least one axial direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0869—Devices involving movement of the laser head in at least one axial direction
    • B23K26/0876—Devices involving movement of the laser head in at least one axial direction in at least two axial directions
    • B23K26/0884—Devices involving movement of the laser head in at least one axial direction in at least two axial directions in at least in three axial directions, e.g. manipulators, robots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/245—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/49—Scanners
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present invention is directed to an apparatus for producing a three-dimensional object by means of a generative layer construction method. It also relates to a generative layer construction process itself. Generative production processes or generative layer construction processes can be used to produce a large number of different types of objects. Examples include dental crowns, engine blocks or shoes. Here are different materials, such. As plastic powder, metal powder, foundry sand, etc. are used. The basic sequence of such a method and the basic structure of a corresponding device are described, for example, in EP 0 734 842 A1 using the example of a laser sintering method.
  • a laser with associated scanning device is provided, by means of which a solidification of the powder is possible at all points of the construction field.
  • the accuracy with which details of the object can be produced within an object cross-section depends, inter alia, on the diameter of the laser beam used for the powder consolidation.
  • the diameter of the laser beam on the powder layer has a value between a few tens and a few hundred micrometers.
  • the problem arises that the laser beam from the scanner no longer approximately meets perpendicularly to a powder layer to be selectively solidified, but impinges excessively obliquely at the points of the powder layer farthest from the scanning device. This leads to an unintentionally strong increase in the effective area of the laser on the powder layer and thus to a reduction in the level of detail.
  • German patent application DE 43 02 418 AI deals with the problem that the laser beam can not be performed arbitrarily fast over a layer.
  • the patent application firstly describes a stereolithographic process, but also mentions powder as a material.
  • DE 43 02 418 Al it is proposed to provide a plurality of radiation sources, each with an associated deflection device for the laser beam. This allows different areas of a construction field to be irradiated and solidified simultaneously. Either a separate region of the layer is assigned to each laser beam or a region is solidified in such a way that several rays alternately brush adjacent line-shaped regions.
  • WO 2014/199144 A1 deals with the problem that, despite the simultaneous irradiation of a building material layer with a plurality of lasers, time losses occur at different locations.
  • a problem here is that, depending on the shape of an object cross-section, there are deflection devices which remain almost inactive, since there are only a few sites to be solidified in the area of the building material layer assigned to them, while other deflection devices apply the laser radiation to all locations within their area Work area.
  • the solidification time for an object cross section is then determined by the slowest Determined link in the chain, namely that deflection device that has to consolidate the largest area in their work area or requires the longest time for solidification in their workspace.
  • WO 2014/199134 A1 suggests an overlapping of the work areas assigned to the deflecting devices, so that an almost inoperative deflecting device can be used in an overlapping area with the working area of a neighboring deflecting device.
  • the automatic decision as to which positions in an overlap region should be used which laser, in other words, the coordination of the solidification of the material on this directed rays, not always easy.
  • An improvement is sought in particular to the effect that the implementation of the layer construction process is simplified.
  • a device of the type mentioned above has:
  • An entry device for the controlled directing radiation of at least one radiation source on an object cross-section corresponding areas of a coated layer of a building material within the construction field.
  • the entry device is designed and / or controlled in operation so that it can direct a plurality of rays simultaneously to different regions of the applied layer, and so that each of the plurality of rays exclusively to a (particular fixed) subregion of the layer assigned to it of the building material can be directed, wherein the subregion is smaller than the entire construction field and by the total number of subregions the entire construction field is covered.
  • the device for producing a three-dimensional object further comprises a control unit for controlling the insertion device, such that each of the rays, where it impinges on the layer, acts on the building material, in particular so that it is solidified. At least one of the subregions partially overlaps, but not completely, with at least one other of the subregions. An overlap sum of overlap areas formed by such overlaps comprises at least 10% of the total area of the construction field.
  • the control unit (10) is designed to simultaneously direct a plurality of beams onto at least a portion of an overlap area such that the impact areas of the plurality of beams overlap.
  • a certain overlap of subregions is present, so that when solidifying a jet, in the relevant subregion only a few points are solidified, can be used in an adjacent subregions in which many points must be solidified.
  • the impact areas overlap with the simultaneous solidification with several beams, then this brings a speed gain, since the individual beams have to enter less energy and thus can be moved faster over the building material.
  • an at least partially common, ie connected, melt pool of the building material is generated, whereby it can be realized, for example, that the multiple beams can be used synergistically for melting the building material.
  • the device according to the invention makes it possible in a simple manner to automatically coordinate a plurality of beams which are simultaneously directed to a region thereof for solidifying the building material.
  • the shape of the object cross-section to be consolidated need not be taken into consideration, since the impact areas of the beams are merely aligned with one another.
  • the invention is preferably applicable to devices which use electromagnetic radiation of the same wavelength to solidify the building material, it can equally be applied to devices in which solidification is by means of particle beams (for example by means of electrons).
  • the area of the overlap area of the impact areas should be at least 80
  • % more preferably substantially 100%, of the area of one of the landing areas of the plurality of beams.
  • the area in which energy is registered more narrowly bounded, so that the temperature distribution in the construction field can be better controlled.
  • An overlap of exactly 100% can not be achieved, in particular, if the impact areas have a similar size but a different shape. Even when using, for example, two beams of the same wavelength, this problem can occur when the two beams impinge at different obliquely on the building material, as already mentioned at the outset.
  • the total energy introduced by the plurality of beams in the overlap region of the impact points is equal to a pre-determined solidification energy for the build material at a location of the object cross section outside the overlap region. In this way, as homogeneous as possible energy input into the building material is provided, regardless of the number of rays used simultaneously for solidification.
  • control unit is designed so that it directs exactly two beams, namely a first beam and a second beam, at the same time on at least part of an overlap area.
  • the coordination of the beams and in particular the total energy registered in the building material by a plurality of beams simultaneously becomes very simple, in particular if the two beams register the same energy in the overlapping area.
  • the two beams are moved over the part of the overlap area before intersecting their impingement areas with monotonically decreasing distance of the impingement areas one after the other for solidification of the building material until the impingement areas overlap.
  • Such a procedure avoids strong local temperature differences due to the increase in the number of simultaneously operating beams.
  • at first only the first beam is directed onto the part of the overlapping area and contributes at least 100%, preferably substantially 100%, of the hardening energy predetermined in advance into the building material (11).
  • the second beam is additionally directed to the portion of the overlap region, wherein substantially at the beginning of the overlap of the impingement areas of both beams, the solidification energy introduced by the first beam is monotonically reduced and, at the same time, the solidification energy introduced by the second beam is monotonically increased until over - Cutting the impact areas with at least 80%, preferably with substantially 100%), together by the first beam and the second beam together substantially at least 100%, preferably substantially 100%, the predetermined solidification energy in the Construction material can be entered. With such a control of the registered by the rays of energy in the material can be avoided in particular strong temperature differences in a small space.
  • the two beams after intersection of their impingement areas are at least 80%, preferably substantially 100%, monotonically increasing the distance of the impingement areas one after another to solidify the beam Construction material moves over the overlap area until only one of the two beams is directed to the overlap area.
  • Particularly preferred is the procedure that, when the impact areas overlap with at least 80%, preferably with substantially 100%, of the two beams altogether at least 100%, preferably substantially 100%, of the previously determined solidification energy into the construction material be registered and with monotonously increasing distance of the impact areas, the energy introduced by one of the two beams is monotonically reduced and the energy introduced by the other beam is monotonously increased, so that finally only one of the two beams is directed to the part of the overlap area and there at least 100%, preferably substantially 100%), which enters pre-determined solidification energy.
  • At least one of the subregions partially or completely overlaps with more than one other of the subregions.
  • at least one of the subregions partially or completely overlaps with more than one other of the subregions.
  • Subregions an area in which it overlaps simultaneously with at least two other subregions.
  • a multiple partial overlap of at least one partial region with other partial regions is realized, in particular such that even a surface is formed which is formed from at least three, preferably even four, partial regions overlapping one another in the surface.
  • This increases in the area of this area inter alia, the synergy effect of several directable to this area rays that can complement each other even better.
  • all subregions have the same dimensions. This simplifies, for example, the clarity for a user and also for the control of the beams.
  • the subregions may have any shape, preferably at least one subregion, particularly preferably all subregions, is rectangular, in particular square.
  • each of the subregions overlap with the subregions adjacent to it.
  • the overlapping area with an adjacent partial region is the same for all overlapping partial regions.
  • a plurality of the subregions overlap with the subregions adjacent thereto and an extension of the overlapping of the sides in a first direction of the arrangement of the subregions is different from an extension of the overlap of the sides in a transverse, preferably perpendicular to the first direction two - direction.
  • the sides of two adjacent subregions substantially overlap one another along their entire extent in a spatial direction. This in turn simplifies the above-mentioned clarity and controllability.
  • the construction field is rectangular, in particular square, and there are four partial regions which are arranged in the corners of the construction field.
  • a total of at least three subregions preferably four, more preferably at least six and most preferably at least ten subregions, are present.
  • the number of subregions is even and in particular that the subregions are arranged at least in a row of two.
  • the subregions are arranged relative to one another such that at least part of their arrangement substantially or partially describes an open or closed circular or elliptical shape. This may, but does not necessarily mean that the construction field itself describes a (semi-) round or (semi-) elliptical shape at its outer boundaries.
  • angular subregions can also be arranged partially overlapping one another in such a way that together they do not describe a line or row and column arrangement, but rather a (partial) circle or a (partial) ellipse. It can also be provided in general in the context of this specific embodiment that in the middle of such an arrangement no construction field is, but the arrangement defines an open or closed (circular or elliptical) annulus.
  • the overlap total comprises at least 20%, particularly preferably at least 40%, of the total area of the construction field.
  • an excessively large overlap amount means that the construction field can not be chosen arbitrarily large due to the above-described necessity of avoiding excessive angles of the beams.
  • the overlap sum comprises at most 80%, particularly preferably at most 60%, of the total area of the construction field.
  • a generative layer construction method according to the invention for producing a three-dimensional object by means of a device has the following steps:
  • the picking device directing a plurality of beams simultaneously to different regions of the applied layer
  • each of the plurality of jets is directed exclusively to a subregion of the layer of the building material assigned to it, wherein the subregion is smaller than the entire construction field and the entire construction field is covered by the total number of subregions, at least one of the subregions having at least one others of the subregions partially but not completely overlapped and an overlap sum of overlap areas formed by such overlaps comprises at least 10% of the total area of the construction field,
  • the insertion device being controlled in such a way that each of the rays in its impact area, ie where it impinges on the layer, acts on the building material, in particular in such a way that it solidifies,
  • a plurality of beams are simultaneously directed to at least a portion of an overlap area such that the landing areas of the plurality of beams overlap.
  • FIG. 1 shows the schematic structure of an embodiment of a device according to the invention.
  • FIG. 2 shows a plan view of the construction field with subregions swept by laser beams for an exemplary embodiment with four laser beams.
  • FIG. 3 shows a plan view of the construction field with subregions swept by laser beams for an exemplary embodiment with six subregions.
  • FIG. 4 shows a plan view of the construction field with subregions swept by laser beams for an embodiment with ten subregions.
  • FIG. 5 shows a plan view of the construction field with subregions swept by laser beams for an exemplary embodiment with five subregions.
  • 6 shows a plan view of two overlapping partial regions of the construction field to illustrate a solidification according to the invention by a plurality of beams in the overlapping region.
  • FIG. 7 shows a plan view of two overlapping partial regions of the construction field for the purpose of illustrating an alternative solidification according to the invention by a plurality of beams in the overlapping area.
  • FIG. 8 shows a plan view of two overlapping partial regions of the construction field, to illustrate a procedure according to the invention for changing the number of beams used simultaneously for solidifying a region.
  • the present application generally refers to a construction method under the term "generative production method" in which objects are produced from an informal material, in particular a powder, by stratified solidification using radiation energy, in particular as described in more detail in the following examples, laser energy Below, therefore, a “laser” is described by way of example as a radiation source, without restricting the content of this disclosure.
  • the present invention can be implemented not only in connection with laser radiation, but also in connection with other electromagnetic radiation, but in particular also in connection with particle radiation (eg electron beams) can be implemented.
  • the present application is directed to such an original molding method in which an object in the desired shape is produced without the aid of external molds by irradiating a laser with those sites in a building material layer to be solidified into a cross section of the object to be manufactured be changed, wherein the point of action of the laser in the layer is changed by means of a scanner.
  • a method are selective laser melting, selective laser sintering, and stereolithography techniques.
  • solidifying in the present application is understood to mean a process of irradiating a liquid or powdery building material in such a way that the building material is partially or completely melted at these locations by the heat energy introduced by the radiation, so that it is after its Cooling is present as a solid describes.
  • a predetermined solidification energy corresponds to the heat energy to be introduced per unit area for the solidification process. Therefore, if a "pre-determined amount of energy to be entered" is mentioned below, this means that within the surface area to which this statement relates, the heat energy to be introduced per unit area is entered at all points for the solidification process.
  • the term "impact area” refers to the area of the area on the building material surface within which a beam interacts with the building material, that is, absorbs heat.
  • the area in which the consolidation takes place is solidification of the building material.
  • an overlap of impingement areas is then preferably present when the areas assigned to the individual beams in which solidification takes place overlap. If solidification is caused by the jets forming a molten bath in the constituent material layer, respectively, an overlap of jets is preferred when they are associated with the individual jets
  • the term "beam” is not limited to radiation that impinges on a powder layer almost punctiform.
  • the term also includes radiation which, for example, strikes a line or a beam spot, which due to its large extent would no longer be referred to as "punctiform".
  • Punctiform it is important that a ray scans sequentially the subregion assigned to it.
  • the apparatus shown in Fig. 1 comprises a building container 1, in which a support 2 is provided for supporting an object 3 to be produced.
  • the carrier 2 can be moved via a height adjustment device 4 in the vertical direction in the construction container 1.
  • the plane in which applied powdery building material is solidified defines a working plane.
  • the part of the working level which is enclosed by the building container 1 or else a specially delimited area within the part of the working level enclosed by the building container 1 is referred to as building area 5.
  • the extent of the construction field is identical to the horizontal extent of the support.
  • a laser 6 is provided, which generates a laser beam 7, which is focused on deflection devices 8 and 9 on the construction field 5.
  • FIG. 1 shows by way of example two deflection devices (scanners) to which light is supplied from the laser 6.
  • the laser beam 7 generated by the laser 6 is thereby split (not shown in detail) into a laser beam 7a, which is reflected at the deflector 8, and a laser beam 7b, which is reflected at the deflector 9.
  • the deflection devices 8 and 9, which are shown only schematically, can each be a galvanometer mirror pair, which is controlled by a controller 10.
  • the controller 10 accesses data that includes the structure of the object to be produced (a three-dimensional CAD layer model of the object).
  • the data contain precise information about each layer to be consolidated, each layer to be consolidated being associated with a cross-section of the object to be produced.
  • the deflection devices 8 and 9 are controlled in such a way that the laser beams 7a and 7b are directed to those points of the construction field 5 at which solidification in a layer of the applied powdery building material is to be effected by the action of the laser light.
  • a feeding device 11 is shown schematically, can be supplied with the powdered building material for a layer.
  • the building material is then applied in the construction field 5 with a certain layer thickness and smoothed.
  • the carrier 2 is lowered layer by layer, applied a new powder layer and solidified by means of the laser beams 7a and 7b at the respective object corresponding points of the respective layer in the building field.
  • pulverulent build-up material it is possible to use all powders or powder mixtures suitable for a laser sintering process or laser melting process.
  • powders include e.g. Plastic powders such as polyamide or polystyrene, PAEK (polyaryletherketones), elastomers such as PEBA (polyether block amides), metal powders (e.g., stainless steel powder, but also alloys), plastic-coated sand, and ceramic powders.
  • a plurality of deflection devices is provided. The number need not be limited to two deflection devices, as exemplified in FIG. 1. As will be explained below with reference to FIG. 2, each deflection device is assigned a partial region of the construction field 5. This means that the (partial) region into which the laser beam can be deflected by means of a deflection device is limited and comprises only a fixed part of the construction field.
  • Fig. 2 shows an embodiment of the invention, in which four laser beams are present, which can be directed to the construction field.
  • Fig. 2 shows a plan view of the construction field, which is square in this embodiment. Shown schematically are four sub-regions 7a ', 7b', 7c 'and 7d', which are those sub-regions that can be swept by corresponding laser beams 7a, 7b, 7c and 7d. This means that a partial region 7a 'is assigned to the laser beam 7a, a partial region 7b' is assigned to the laser beam 7b, etc. In particular, it can be seen in FIG. 2 that the square partial regions 7a ', 7b', 7c 'and 7d' are partially integral with one another overlap.
  • the partial regions 7a 'and 7b' overlap each other in a horizontal direction in FIG.
  • the arrangement just described of the sub-regions swept by the laser beams in the construction field 5 causes the building material to solidify in the overlapping areas of two subregions both with the laser beam associated with one subregion and with the laser beam associated with the other subregion. Since preferably the individual subregions associated laser beams are directed simultaneously to the construction field, causes the selected arrangement that in the overlapping surfaces, a solidification of the building material can take place faster because there two laser beams can solidify the material at the same time.
  • the areas marked A are reached by only one laser beam.
  • the areas marked B can be reached by two laser beams.
  • the area marked C can be reached by four laser beams.
  • each of the two laser beams can enter half of the energy required for solidification Laser beams are coated so that a track of the one laser beam between each two adjacent tracks of the other laser beam Ray is lying.
  • the solidification takes place in a corresponding manner with four laser beams.
  • FIG. 6 shows a plan view of two overlapping partial regions 30 and 40 of the construction field to illustrate the procedure according to the invention for solidifying the construction material in the overlapping region of two partial regions with a plurality of beams.
  • the two subregions 30 and 40 are each rectangular and extend horizontally between the sides 30a and 30b and 40a and 40b, respectively.
  • the overlapping area extends horizontally between the lines 40a and 30b in FIG. 6.
  • the beams are coordinated with one another in such a way that the impact areas of the beams are on overlap the layer when painting the building material.
  • reference numeral 50 designates an impact area of a first laser beam
  • reference numeral 60 designates the impact area of a second laser beam.
  • the two impact areas are approximately circular.
  • the overlapping area of both impact areas 50 and 60 is designated by the reference numeral 55.
  • a first laser beam is directed onto the impingement region 50 via the deflecting device 8
  • a second laser beam is directed onto the impinging region 60 via the deflecting device 9.
  • the two impact areas are now moved synchronously over the construction field within the overlapping area, wherein preferably the size of the area of the overlapping area 55 does not change.
  • the energy of the two beams deflected by the deflection devices 8 and 9 is correspondingly reduced such that the energy introduced in the overlap region 55 substantially equals the introduced energy at other locations in the applied build-up material layer ,
  • the beam associated with the impact area 50 could provide 50% of the energy to be input, and the beam associated with the impact area 60 could also provide 50% of the energy.
  • the first beam (assigned to region 50) to introduce only 30% of the energy and for the beam associated with region 60 to introduce 70% of the energy.
  • any combination is possible as long as ultimately at least 100% of the energy to be entered in advance is entered in the overlap area 55.
  • the energy to be introduced in advance for solidifying the building material depends on the type of building material, its densification in the application of layers, the working temperature at which the radiation is directed to the building material and even more parameters. When changing the size of the area of the overlapping area, it is preferred that by the individual
  • the simultaneous solidification within the overlapping area can also take place in such a way that adjacent laser tracks to which different laser beams are assigned are simultaneously solidified.
  • the overlapping area of FIG. 7 corresponds to that of FIG. 6.
  • the impact areas 50 and 60 are no longer shown.
  • Fig. 7 shows resulting beam traces 50 'and 60' which are formed by the process of impact regions 50 and 60 over the construction field.
  • the impact areas 50 and 60 would first be moved along the two upper tracks 50 'and 60' in FIG.
  • Fig. 3 shows an embodiment of the invention, in which the rectangular construction field is covered by six subregions, each associated with a laser beam. For the sake of clarity, only the outlines of two subregions are highlighted. However, the position of the subregions is indicated by curly brackets. In the areas designated A, again only one laser beam is active. In the areas designated B, there is an overlap of two subregions with each other, and in the areas denoted C there is an overlap of four subregions. In particular, it can be seen in Fig. 3 that the overlap of partial regions in the horizontal direction of the figure has a different size than the overlap in a vertical direction in the figure. As a result of the arrangement of the partial regions in FIG. 3, more than 50% of the construction field can be exposed with more than one laser beam.
  • Fig. 4 shows an embodiment in which ten partial regions are shown instead of six partial regions.
  • the arrangement of the subregions and also of the individual surfaces A, B and C is corresponding to the arrangement in FIG. 3. It can be seen from FIG. 4 that the invention can be implemented with any number of subregions. Even with eight, twelve, fourteen, etc. subregions, the corresponding division of the construction field would be analogous.
  • Fig. 5 shows a further embodiment with five subregions. Four subregions are arranged as shown in FIG. Only the additional fifth subregion is highlighted and positionally marked with curly braces. In the areas designated A, again only one laser beam is active.
  • the additional fifth partial region means that five laser beams can be active at the same time in the center of the construction field (area D).
  • a corresponding procedure as in FIG. 5 is also with another odd-numbered one Number of laser beams possible.
  • additional subregions may also be placed in the middle in the arrangements of FIG. 3 and FIG. 4.
  • FIG. 8 shows, like FIGS. 6 and 7, a plan view of two overlapping partial regions of the construction field in this example.
  • the impact regions 50 and 60 of two laser beams are again shown in the overlap region of the two subregions between the lines 40a and 30b.
  • An inventive method can, for example, look like the following: i) First, the solidification in the overlapping area takes place only with the first one
  • the laser beam contributes at least 100%, preferably substantially 100%, of the energy which has been predetermined in advance and is to be entered for solidification of the building material.
  • Structural material layer has been directed within the overlap area, the Immediately at the beginning of its movement over the cross-section of the object within the overlap area, 0% of the energy to be entered in advance.
  • the distance between the two landing areas 50 and 60 is gradually reduced. This can be done, for example, such that the impact areas are moved over the construction field at different speeds, and, as shown in FIG. 8, for example, the impact area 50 in the movement follows the impact area 60, but is moved at a higher speed than the impact area 60.
  • the energy introduced by the first laser is reduced in accordance with a monotonically decreasing function. To the same extent, however, the energy introduced by the second laser is increased.
  • the procedure is not limited to the example of FIG. 8.
  • the impact area 60 could just as well move toward the impact area 50, for example when the second laser beam travels after the first laser beam.
  • both beams are synchronized with at least 80% overlap of their impingement areas, preferably substantially complete intersection of their impingement areas, over an object cross-section to be solidified 8, in the overlapping area shown in FIG.
  • the speed of the second beam is reduced, so that the area of the overlap area gradually decreases and finally the second beam runs after the first beam.
  • the energy introduced by the second beam is reduced following a monotonically decreasing function and the energy of the first beam is correspondingly increased.
  • the solidification in the overlapping area is performed only by the first beam, which then at least 100%, preferably substantially 100%, enters a pre-determined set energy to be entered.
  • the procedure described with the aid of FIG. 8 is not limited to two beams used simultaneously for solidification in the overlapping area.
  • the second beam in FIG. 8 when the second beam in FIG. 8 is connected in, it does not necessarily have to enter essentially 0% of the energy to be entered in advance into the material, even if the impact areas do not yet overlap.
  • the added beam could initially input 20% of the pre-determined energy.
  • a delayed cooling of the material after solidification with the first jet would be effected if the second jet travels after the first jet. If the first jet first precedes the second jet, the second jet would preheat the material before solidifying it with the first jet.
  • the energy of the wegzugateden beam before Wegsc might not inevitably reduced to 0%, but could be previously reduced, for example, to only 20%, even if the impact areas no longer overlap.
  • a procedure described with reference to FIG. 8 also permits controlled "encounters" of two or more beams during joint solidification within an overlapping area. It then presents no problem if two or more beams come together very closely during joint solidification or the associated impact areas intersect at times, although the impact areas do not overlap most of the time.
  • the described embodiments of the invention can be modified in many ways:
  • the beams need not all be generated by a single radiation source that interacts with multiple deflectors. It is quite possible to allocate an individual radiation source to all or even only individual ones of the deflection devices or to assign a number of deflection devices, which is smaller than a total number of deflection devices, to a radiation source. In addition, not all radiation sources necessarily have to be the same, although this is preferably the case.
  • the controller 10 must ensure that exposure outside the construction field is prevented. (The theoretically possible by a galvanometer mirror range in which a beam can radiate, so is limited by the controller 10).
  • the invention is also applicable in a case where the construction field and / or the partial regions assigned to the beams are not rectangular.

Abstract

L'invention concerne un dispositif et un procédé permettant de produire un objet tridimensionnel. L'objet (3) est construit sur au moins un support (2) déplaçable en hauteur. L'étendue horizontale du ou des supports définit une zone de construction (5). Un dispositif d'injection (6, 8, 9) dirige le rayonnement commandé d'au moins une source de rayonnement sur une partie d'une couche appliquée qui correspond à une section transversale de l'objet Le dispositif d'injection (6, 8, 9) dirige simultanément une pluralité de rayons sur des régions différentes de la couche appliquée. Chaque rayon n'est dirigé que sur une région partielle de la couche qui lui est attribuée, la région partielle étant plus petite que la totalité de la zone de construction (5). La totalité de la zone de construction (5) est recouverte par le nombre total de régions partielles. Le dispositif d'injection (6, 8, 9) est commandé par une unité de commande (10). Au moins une des régions partielles est en partie, mais non totalement, en chevauchement avec au moins une autre région partielle. La somme de chevauchements formée par lesdits chevauchements couvre au moins 10 % de la surface totale de la zone de construction.
EP15819842.4A 2015-01-07 2015-12-30 Dispositif et procédé génératif de construction par couches permettant de produire un objet tridimensionnel au moyen d'une pluralité de rayons Withdrawn EP3242762A1 (fr)

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PCT/EP2015/081441 WO2016110440A1 (fr) 2015-01-07 2015-12-30 Dispositif et procédé génératif de construction par couches permettant de produire un objet tridimensionnel au moyen d'une pluralité de rayons

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